DE112014004977T5 - diffuser - Google Patents

Abstract

A diffuser panel for a vehicle exhaust system includes a body having a primary opening and a plurality of secondary openings circumferentially spaced from one another about the primary opening. In one example, the diffuser disk is positioned between an exhaust manifold and a catalyst. Exhaust gas from the exhaust manifold passes through the primary and secondary openings in the diffuser disk to produce a thoroughly mixed flow that is evenly distributed via an inlet into a catalyst substrate, and further for an oxygen sensor to be capable of determining the chemical composition of the exhaust gas To accurately measure the engine cylinder.

Description

Cross-reference to related application

This application claims the benefit of US Patent Application No. 14 / 068,047, filed Oct. 31, 2013.

Technical area

The present invention relates to a diffuser disk for a vehicle exhaust system.

Background of the invention

Exhaust systems are well known and widely used in internal combustion engines. Typically, an exhaust system includes exhaust pipes that direct hot exhaust gases from an engine exhaust manifold to other downstream components of the exhaust system, such as catalytic converters, mufflers, reflective mufflers, etc. As is known, a catalyst converts toxic by-products of the exhaust gases by means of catalyzed chemical reactions into less toxic substances. The catalyst includes a substrate positioned in a housing having an exhaust inlet and an exhaust outlet. As the exhaust gas flows through the substrate, pollutants such as carbon monoxide, unburned hydrocarbon and nitrogen oxides are converted to less toxic materials such as carbon dioxide and water.

The use of mixing elements positioned upstream of the catalyst in an attempt to efficiently direct the flow of exhaust gas into the substrate is known. While these disks have proven effective, there is always a need for further increasing the efficiency of emission conversion.

Summary of the invention

In an exemplary embodiment, a diffuser panel for a vehicle exhaust system includes a body having a primary opening and a plurality of secondary openings circumferentially spaced from one another about the primary opening. In one example, the diffuser disk is positioned between an exhaust manifold and a catalyst. Exhaust gas from the exhaust manifold passes through the primary and secondary openings in the diffuser disk to produce a thoroughly mixed flow that is evenly distributed via an inlet into a catalyst substrate.

In a further embodiment of the foregoing, the body of the diffuser disc comprises an annular body.

In a further embodiment of any of the above, the primary opening comprises a single, central opening defining a central axis, and the plurality of secondary openings comprise a plurality of slots circumferentially spaced about the central axis.

In a further embodiment of any of the above, the annular body has an upstream side configured to face an exhaust manifold and a downstream side configured to face a catalyst substrate, and wherein the primary and secondary sides the secondary ports cooperate to form a plurality of exhaust gas flow paths from the exhaust manifold to the catalyst substrate.

In a further embodiment of any of the foregoing, the diffuser disk has a flange formed around a circumference of the annular body and extending in the downstream direction.

In a further embodiment of any of the foregoing, the diffuser disk has a plurality of legs extending from the flange in the downstream direction.

In another exemplary embodiment, a vehicle exhaust system includes an exhaust manifold having a plurality of channels configured to receive exhaust gases from an engine and a catalyst having a housing having an inlet end configured for attachment to an exhaust manifold outlet , The housing defines an internal cavity. In the inner cavity, a substrate is positioned. A diffuser disk is positioned upstream of the substrate and has a primary opening and a plurality of secondary openings circumferentially spaced around the primary opening.

In a further embodiment of any of the above, the diffuser disk includes a flange formed about a circumference of the annular body and a plurality of legs secured to an inner surface of the exhaust manifold such that an outer periphery of the flange is spaced radially inwardly from the inner surface ,

In another embodiment of any of the above, the plurality of slots extend outwardly from the annular body in a downstream direction such that recesses are formed in the upstream side and projections corresponding to the downstream side.

Brief description of the drawings

1 Figure 11 is a side view of an exhaust component assembly incorporating the present invention.

2 FIG. 12 is a perspective view of the exhaust component assembly. FIG 1 partially in section to show a diffuser disk.

3 is a perspective view of a downstream side of the diffuser disc 2 ,

4 is a perspective view of an upstream side of the diffuser disc 2 ,

5 FIG. 12 is a perspective view of an intake passage side of an exhaust manifold and diffuser disk assembly. FIG.

6 is a perspective view of an outlet side of the assembly from 5 ,

7 is another example of a diffuser disk.

8th is another example of a diffuser disk.

Detailed description

In 1 is an exhaust component assembly 10 shown for a vehicle exhaust system. The exhaust component assembly 10 has an exhaust manifold 12 on, the exhaust gases through several channels 16 from a vehicle engine 14 receives. As is known, every channel is 16 an engine cylinder 18 assigned. At the in 1 example shown is the engine 14 a six-cylinder engine, with the manifold 12 a set of cylinders 18 is assigned to the right. Another manifold, in the same way as the one in 1 is shown assigned to a set of cylinders on the left side.

The manifold 12 consists of an outer casing or housing 20 with several branch sections 22 that become a common outlet 24 extend. Each branch section 22 is one of the channels 16 assigned. The outlet 24 directs the exhaust gases to a downstream exhaust component such as a catalyst 26 , The catalyst 26 has an outer casing 28 ( 2 ), which is between a first end 30 and a second end 32 extends. The outer housing 28 limits an internal cavity 34 in which one or more substrates 36 are housed, as in 1 is shown. In certain designs, the substrates may be covered with an insulating mat (see optional mat 36a in 1 ). The catalyst 26 defines a central axis A from the first end 30 to the second end 32 runs.

The outlet 24 of the elbow 12 is for attachment to the first end 30 of the outer casing 28 educated. At the second end 32 of the outer casing 28 is an outlet pipe 38 attached. As is known, the outlet pipe conducts 38 the exhaust gases to downstream exhaust components.

The exhaust component assembly 10 has a diffuser disk 40 on, the upstream of the substrate 36 of the catalyst 26 is positioned as in 2 shown. In one example, the diffuser disk includes 40 an annular body 42 ( 3 ), which is a primary opening 44 and several secondary openings 46 which is around the primary opening 44 are circumferentially spaced from each other. In the example shown, the primary opening comprises 44 a single, central opening, and the multiple secondary openings 46 are over several slots 48 educated.

The primary opening 44 defines a central axis with that of the catalyst 26 defined center axis A matches. The annular body 42 is by an inner circumference 50 (the the primary opening 44 forms) and an outer circumference 52 Are defined. The material between the inner 50 and the outside 52 forms the ring shape and has the slots 48 on.

The several slots 48 are circumferentially spaced from each other about the central axis A, as in Figs 3 and 4 shown. Every slot 48 defined compared to the other slots 48 a clear flow direction. The central primary opening 44 forms an axial flow path for the exhaust gases and the slots 48 form a plurality of generally tangential flow paths that are in one direction with respect to the inner circumference 50 of the body 42 tangential. Through the slots 48 is introduced into the exhaust stream, which mixes with the axial flow, a swirling, thus exhaust evenly over the substrate 36 can be distributed, resulting in uniform mass flows through the substrate.

The annular body 42 has an upstream side 56 that the exhaust manifold 12 facing, and a downstream side 58 on the catalyst substrate 36 is facing. The primary opening 44 and the slot openings 46 Act together so that multiple exhaust gas flow paths from the exhaust manifold 12 to the catalyst substrate 36 are formed. Every slot 48 runs from the annular body 42 so in the downstream direction outward, that in the upstream side 56 wells 60 ( 4 ) and in the downstream side 58 corresponding, curved projections 62 ( 3 ) are formed. Every lead 62 has a downstream facing convex side 64 and an upstream facing concave side 66 on.

In one example, the annular body 42 a flange 70 on, around the outer circumference 52 is formed and located in the downstream direction of the body 42 extends away. From the flange 70 extend several legs in the downstream direction 72 , The legs 72 are around the flange 70 spaced apart in the circumferential direction. Every leg 72 has a first section 74 that is different from the flange 70 extends radially outward, and a second portion 76 which extends in a downstream direction to a distal end 78 extends. A curved section 80 forms the transition between the first section 74 and the second section 76 ,

The legs 72 are for attachment to the exhaust manifold housing 20 executed. In the 5 to 6 is the diffuser disk 40 when installed in the outlet 24 of the outer casing 20 shown the manifold. The legs 72 are on an inner surface 82 of the outer casing 20 appropriate. The legs 72 can on or with the inner surface 82 welded, brazed, fastened, etc.

In one example, the housing is 20 from a first coat 90 and a second coat 92 formed, which are attached to each other ( 6 ). The coats 90 . 92 may be attached using any of various methods including, for example, welding or brazing. The diffuser disk 40 is positioned within an internal cavity, which is between the coats 90 . 92 is formed, and an outer surface 94 ( 4 ) of the second section 76 every leg 72 is on the inner surface 82 appropriate. The coats 90 . 92 can take up the legs 72 wells 96 exhibit. Because of the first section 74 and the curved portion 80 the legs is an outer circumference of the flange 70 then, if the diffuser disk 40 on the housing 20 is attached, over a small air gap 98 from the inner surface 82 spaced radially inwardly ( 6 ). This can cause a thermal expansion between the various components, ie the coats 90 . 92 and the disc 40 , be easily compensated.

In another embodiment, the in 7 shown points the disc 40 You may not put your legs up and you might see the ring-shaped body 42 directly on the inner surface 82 of the housing 20 to be appropriate.

In 8th is another example of a diffuser disk 140 with a primary opening 144 and several secondary openings 146 shown circumferentially spaced from each other. The secondary openings 146 are smaller than the primary opening 144 ,

As in 1 shown, the housing indicates 20 a manifold sensor support portion 100 on, near the outlet 24 located. With this bracket section 100 a first oxygen sensor S1 is connected. The outlet pipe 38 has a sensor support portion 102 which is connected to a second oxygen sensor S2.

The diffuser disk 40 is used to thoroughly mix the exhaust gases and over an entire area of an inlet end 104 of the substrate 36 evenly distributed, thereby increasing the catalyst utilization efficiency. Furthermore, the diffuser disc allows 40 in that exhaust gases from combustion events of individual cylinders are mixed and directed in such a way that the oxygen sensor (S1) is capable of accurately and accurately measuring the chemical composition of the exhaust gas of each cylinder, resulting in reduced fuel consumption and increased catalyst efficiency. This will allow customers to readily comply with certain air quality requirements for the various vehicle models. In addition, the diffuser disc prevents 40 in embodiments, the one with a mat 36a coated substrate 36 have exhaust gases at high speed in the mat area in the housing 28 thus reducing the risk of the mat becoming worn.

While one embodiment of this invention has been disclosed, one of ordinary skill in the art will recognize that certain modifications would fall within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims (20)

Diffuser disc for a vehicle exhaust system, with: a disk body having a primary opening and a plurality of secondary openings circumferentially spaced around the primary opening. A diffuser disk according to claim 1, wherein the primary aperture comprises a single central aperture. The diffuser disk of claim 1, wherein the plurality of secondary openings comprises a plurality of slots. The diffuser disk of claim 1, wherein the disk body comprises an annular body and the primary opening comprises a single central opening defining a central axis, and wherein the plurality of secondary openings comprise a plurality of slots circumferentially spaced about the central axis. A diffuser disk according to claim 4, wherein each slot defines a unique flow direction. The diffuser disk of claim 5, wherein the central opening defines an axial flow path and each slot defines a tangential flow path. The diffuser disk according to claim 4, wherein the annular body has an upstream side formed to face an exhaust manifold and a downstream side configured to face a catalyst substrate, and wherein the primary and the first side faces secondary openings cooperate so that a plurality of exhaust gas flow paths are formed from the exhaust manifold to the catalyst substrate. A diffuser disk according to claim 7, having a flange formed around a circumference of the annular body and extending in the downstream direction. A diffuser disk according to claim 8, comprising a plurality of legs extending from the flange in the downstream direction. The diffuser disk of claim 9, wherein the plurality of legs are adapted for attachment to an exhaust manifold housing via a mounting interface. A diffuser disk according to claim 7, wherein the plurality of slots are outwardly projected from the annular body in the downstream direction so that recesses are formed in the upstream side and projections corresponding to the downstream side are formed. Vehicle exhaust system with: an exhaust manifold having a plurality of channels adapted for attachment to a motor, a catalyst having a housing with an inlet end adapted for attachment to an outlet of the exhaust manifold, the housing defining an interior cavity, a substrate positioned in the inner cavity, and a diffuser disk positioned upstream of the substrate and having a primary opening and a plurality of secondary openings circumferentially spaced from one another about the primary opening. The vehicle exhaust system of claim 12, wherein the diffuser disc comprises an annular body, the primary aperture comprising a single central aperture defining a central axis, and wherein the plurality of secondary apertures comprise a plurality of slots circumferentially spaced about the central axis. The vehicle exhaust system of claim 13 wherein the annular body has an upstream side and a downstream side and wherein the primary opening forms an axial flow path and the secondary openings form a plurality of swirl flow paths that swirl about the central axis and intermesh with the axial flow path. A vehicle exhaust system according to claim 14, having a flange formed around a circumference of the annular body and extending in the downstream direction. A vehicle exhaust system according to claim 15, having a plurality of legs extending from the flange in the downstream direction. A vehicle exhaust system according to claim 16, wherein the plurality of legs are fixed to an inner surface of the exhaust manifold so that an outer periphery of the flange is spaced radially inwardly from the inner surface. A vehicle exhaust system according to claim 17, wherein the plurality of slots from the annular body extend in the downstream direction so that in the upstream side recesses and in the downstream side corresponding projections are formed. A vehicle exhaust system according to claim 12 having an oxygen sensor positioned in the exhaust manifold, and wherein the primary port and the plurality of secondary ports cooperate to thoroughly mix and distribute exhaust gases over an entire inlet side of the substrate and allow the oxygen sensor To measure the chemical composition of the gas of the engine cylinder via associated channels of the exhaust manifold. A vehicle exhaust system according to claim 12, wherein the substrate is wrapped with a mat and wherein the diffuser disc prevents exhaust gases from entering a mat region in the housing at high speed.

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